KTM Freeride E-XC 2019 Manual

SETUP INSTRUCTIONS 2019

Freeride E‑XC

Art. no. 3213880en

INTRODUCTION

*3213880en*

3213880en

01/2019

INTRODUCTION

Perform the work described in these setup instructions before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make

changes in the interest of technical advancement without at the same time updating this manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop

are not specified here. It is assumed that the work will be performed by a fully trained mechanic with the corre-

sponding HV training.

All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right

to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc.,

without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop produc-

tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-

ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that

does not belong to the regular scope of supply.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission

of the copyright owner.

ISO 9001(12 100 6061)

KTM applies quality assurance processes that lead to the highest possible product quality as

defined in the ISO 9001 international quality management standard.

Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH

Stallhofnerstraße 3

5230 Mattighofen, Austria

This document is valid for the following models:

Freeride E‑XC EU (F3001S1)

1 MEANS OF REPRESENTATION

1.1 Symbols used

The meaning of specific symbols is described below.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

Identifies work requiring expert knowledge and technical understanding. In the interest of your

own safety, only have these jobs performed by correspondingly trained KTM technical person-

nel.

All work identified by this symbol requires a level 1 qualification for high-voltage systems. Only

this qualification authorizes you to perform non-electro-technical work on a vehicle or on units

with a high-voltage system.

All work identified by this symbol requires a level 2 qualification for high-voltage systems.

Only this qualification authorizes you to de-energize the electrical system and perform

electro-technical work in a de-energized state.

All work identified by this symbol requires a level 3 qualification for high-voltage systems. Only

this qualification authorizes you to perform electro-technical work under voltage.

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates a resistance measurement.

Indicates the end of an activity including potential rework.

MEANS OF REPRESENTATION 1

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Indicates a proprietary name.

Name®Indicates a protected name.

Brand™ Indicates a brand available on the open market.

Underlined terms Refer to technical details of the vehicle or indicate technical terms, which

are explained in the glossary.

2 SAFETY ADVICE

2.1 Work rules

The KTM PowerPack does not contain any parts that require maintenance. Do not open the KTM PowerPack

under any circumstances.

Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered

using the number in parentheses. For example: gear segment (70029032000)

During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock

washers) must be replaced by new parts.

In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. The manufacturer instructions for use

must be followed.

After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged

or worn parts.

After you complete the repair or service work, check the operating safety of the vehicle.

2.2 Safety advice

A number of safety instructions need to be followed to operate the product described safely. Therefore read this

instruction and all further instructions included carefully. The safety instructions are highlighted in the text and

are referred to at the relevant passages.

Info

Various information and warning labels are attached in prominent locations on the product described. Do

not remove any information or warning labels. If they are missing, you or others may not recognize dangers

and may therefore be injured.

2.3 Degrees of risk and symbols

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not

taken.

Caution

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are

not taken.

Note

Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

2.4 Fuel, auxiliary substances

Use the operating and auxiliary substances (such as oils and lubricants) specified in the Owner's Manual.

SAFETY ADVICE 2

2.5 Fire hazard

Warning

Fire hazard Damaged rechargeable lithium-ion batteries (KTM PowerPacks) present a fire hazard.

Massive mechanical damage may cause an internal cell short circuit and as a consequence may cause

the battery to self-ignite.

–Contact the KTM customer service immediately if major damage to the rechargeable lithium-ion bat-

tery (KTM PowerPack) has occurred.

There is no particular fire hazard for this vehicle when the rechargeable lithium-ion battery (KTM PowerPack) is

intact.

However, should the vehicle catch fire, inform the fire brigade responsible that an electric vehicle with a

rechargeable lithium-ion battery is on fire.

3 SETUP

3.1 Transport mode

H02712-01

This vehicle was blocked for transport in the software.

To operate the vehicle, the vehicle electronics must be enabled.

This process is conducted during initial setup in KTM Dealer.net.

Enabling ensures that the initial setup in KTM Dealer.net is docu-

mented.

Enabling can be performed either temporarily, e.g. for a test ride,

or permanently for vehicle handover.

Info

Make sure that the vehicle is permanently enabled before

handing it over to the customer.

3.2 Diagnostic connection

F01879-10

Diagnostic connection 1is located under the front rider's seat.

Info

The charging socket is also the diagnostic connection.

3.3 Unpacking and setting up the vehicle

E00851-10

–Remove the box and the plastic packaging.

Info

An assistant prevents the motorcycle from falling over.

To avoid damaging the motorcycle during the setup,

leave the protective film on the vehicle until you have

finished.

–Remove and unpack the separate enclosure and components.

Check that the scope of supply is complete using the enclosed

packing list.

Info

The procedure in the event of missing components is

described in the customer service manual.

–To be in compliance with the homologation of the vehicle,

mount all of the parts in the separate enclosure when assem-

bling the vehicle.

Info

It is not necessary to mount all of the parts in the sepa-

rate enclosure for the vehicle to operate correctly. How-

ever, homologation will not apply if not all parts from

the separate enclosure are mounted.

–Remove the KTM PowerPack. ( p. 29)

SETUP 3

F01844-10

–Have a lift stand available.

Lift stand (78129955100)

–Carefully loosen and remove the tension belt of the footrest

bracket.

Info

An assistant prevents the motorcycle from falling over.

402050-01

–Together with an assistant, take the vehicle off the pallet.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

Info

The procedure in the event of transport damage is

described in the customer service manual.

F01849-10

–Remove the spare key and KEYCODECARD keep in a safe place

for the handover.

–Loosen rubber strap 1and tilt the headlight mask forwards.

E00971-10

–Disconnect the plug-in connector 2of the headlight and the

plug-in connector 3of the ignition lock.

–Lay down the headlight mask carefully to the side and protect

from damage.

F01234-01

–Make sure that the reflectors are glued on to the left and right

fork leg.

» If there are no reflectors stuck on:

–Stick on the reflector.

Info

The reflectors must not be covered by trim

parts.

3 SETUP

F01852-10

–Remove screws 4. Take off handlebar supports.

–Place handlebar supports in required position. Mount and

tighten screws 4.

Guideline

Screw, handle-

bar support

M10 40 Nm (29.5 lbf ft)

Loctite®243™

Info

The handlebar supports can be mounted in four differ-

ent positions.

Position the left and right handlebar supports evenly.

F01842-10

Warning

Danger of accidents A repaired handlebar poses a

safety risk.

If the handlebar is bent or straightened, the mate-

rial becomes fatigued. The handlebar may break as a

result.

–Change the handlebar if the handlebar is damaged

or bent.

–Position the handlebar.

Info

Make sure the cables and wiring are positioned cor-

rectly.

–Position the handlebar clamps. Mount and tighten the screws

evenly.

Guideline

Screw, handlebar

clamp

M8 20 Nm (14.8 lbf ft)

Info

The handlebar clamps and screws are in the accessory

pack.

The markings on the handlebar should be at the center

of the handlebar clamps.

Keep the installed gap widths equal when tightening.

F01853-10

–Secure the handlebar cushion with two cable ties.

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